Suspension ceiling erection method and support assembly employed therein

ABSTRACT

In a method of erecting a suspended ceiling one end of an elongated support member is positioned with reference to a wall member that is secured at a predetermined height thereon. The support member is adjusted to a horizontal position, and appropriate ceiling grid members are supported between the planar upper surface thereon and a wall member secured to a second wall adjacent to the first. The grid members are fixedly secured to depend from overhead structure in a conventional manner, to support acoustic tiles or other ceiling panels thereon. The assembly employed in the method comprises a scaffold on which the elongated support member is mounted, and includes a leveling device to indicate the relationship between the planar upper surface of the support member and horizontal.

[ 1 Oct. 23, 1973 SUSPENSION CEILING ERECTION METHOD AND SUPPORT ASSEMBLY EMPLOYED THEREIN Filed:

Inventors: Dennis G. LeBlanc, 616 Franklin Ave., Hartford; Norman G. LeBlanc, 224 Nott St., Wethersfield, both of Conn.

Feb. 12, 1971 Appl. No.: 114,757

3/1948 Fryzel 269/19 X 1/1970 Owens 214/1 SW Primary Examiner-Reinaldo P. Machado Attorney-Peter L. Costas [57] ABSTRACT In a method of erecting a suspended ceiling one end of an elongated support member is positioned with reference to a wall member that is secured at a predetermined height thereon. The support member is adjusted to a horizontal position, and appropriate ceiling grid members are supported between the planar upper surface thereon and a wall member secured to a second wall adjacent to the first. The grid members are fixedly secured to depend from overhead structure in a conventional'manner, to support acoustic tiles or other ceiling panels thereon. The assembly employed in the method comprises a scaffold on which the elongated support member is mounted, and includes a leveling device to indicate the relationship between the planar upper surface of the support member and horizontal.

2 Claims, 5 Drawing Figures [52] US. Cl. 182/129, 269/307, 269/321 W, 52/741 [51] Int. Cl. E04g 1/00 [58] Field of Search 269/17, 19, 46, 307, 269/321 W; 214/1 SW; 182/129; 33/137 R [56] References Cited UNITED STATES PATENTS 163,410 5/1875 Reisinger 33/137 R 2,272,349 2/1942 Noser 182/129 2,988,318 6/1961 Ferguson 182/129 3,540,548 11/1970 Halsey 182/129 2,725,619 12/1955 Miller 269/17 X 3,417,877 12/1968 Corley 214/1 SW PAIENTEDBMB ms 3.767.008

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,9 fbfi W AHarney PAIENTEDUCIZIHBB 3.767.008 SHEET 3 BF 3 I n venfars Norman 6. LeB/anc Dennis G. LeB/anc 3L By ltfarney SUSPENSION CEILING ERECTION METHOD AND SUPPORT ASSEMBLY EMPLOYED THEREIN BACKGROUND OF THE INVENTION Suspended ceilings consisting of panels supported within tracks or grid work secured to overhead structure have attained a high level of acceptance for a number of reasons. Not only may they be both attractive and functional (e.g., provide desirable acoustical propeties), but they also afford a convenient and very effective means of hiding the existing ceiling with the unsightly pipes, wires, beams and the like that are often present therealong. On the other hand, installation of such ceilings tends to be a rather time consuming and often tedious task. This is due largely to the frequent necessity of checking the height and/or attitude of the grid members during installation to ensure that the resulting ceiling will be horizontal and at a uniform distance above the floor. It is also due in part to the relatively inadequate support that is provided for the grid members in accordance with the heretofore utilized methods.

Accordingly, it is an object of the present invention to provide a'novel method of erecting a suspended ceiling, which is relatively facile and rapid compared to conventional methods, and which results in a ceiling that is horizontal and at a uniform distance above the floor.

It is also an object of the invention to provide a novel assembly for use in the method of the invention which assembly may be produced relatively simply and economically, and is facile and conveneint to employ.

SUMMARY OF THE DISCLOSURE It has now been found that the foregoing and related objectives of the invention can be readily attained in a method for the erection of a suspended ceiling wherein a plurality of wall members are secured at a predetermined height on at least two adjacent walls of a room to provide at least one support element projecting inwardly from each of the walls and lying in a common, substantially horizontal plane. One of the support elements projecting from one of the walls is used to position, substantially at the predetermined height, an end of an elongated support member having a substantially planar upper surface. The elongated support member is adjusted to a position disposing the upper surface in a substantially horizontal attitude, and the support member is fixed in the adjusted position thereof. Thereafter, a plurality of ceiling grid members are supported, at spaced locations along the other wall, upon the support element projecting therefrom and upon the upper surface of the support member to extend therebetween. The grid members so supported are then affixed to overhead structure to provide a depending grid portion for a suspended ceiling.

Normally, the elongated support member is positioned by engaging the end thereof under the support element provided by the wall member. Subsequently, during the erection of the ceiling, the support member is moved to a position of disengagement from under the support element. Most desirably, a multiplicity of cooperating grid elements are supported between and perpendicular to adjacent grid members at spaced locations along the length thereof, so as to define a plurality of subdivisions for support of ceiling panels.

Certain objects of the invention can be attained by the provision of an assembly for use in the previously described method. The assembly comprises a mobile scaffold having an elevated platform thereon, and an elongated support member having a substantially planar upper surface adjustably supported upon the scaffold. The elongated support member is securable on the scaffold in a multiplicity of positions above the platform, and leveling means is provided on the support member to indicate the relationship of the support surface to horizontal. In the preferred embodiments of the assembly, the support member is mounted upon the scaffold by a plurality of posts that are spaced along the length thereof. The posts have means thereon for fixing the support member in adjusted positions, and the support member has secured thereto a device for measuring the distance to the floor.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a front elevational view of a support assembly embodying the present invention and illustrating the manner by which it is used to erect a suspended ceiling;

FIG. 2 is a front elevational view of the upper portion of the assembly of FIG. 1, comprising the means for height adjustment and leveling of the support surface provided thereby;

FIG. 3 is a fragmentary end view along line 3 3 of FIG. 2 drawn to an enlarged scale and illustrating in partial section the portion of the assembly shown therein;

FIG. 4 is an end elevational view of the support assembly of FIG. 1 at an earlier stage during the erection of the ceiling; and

FIG. 5 is a perspective view of the I-beam in the assembly of FIGS. 1 4 and of a partial installation of ceiling grid members, drawn to a slightly enlarged scale and illustrating the manner of installation.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT Turning now in detail to FIGS. 1 4 of the appended drawings, therein illustrated is a support assembly embodying the present invention, including a wheelmounted portable platform or scaffold, generally designated by the numeral 10, having an elevated plank stage portion 12 thereon. Two spaced, parallel, vertically disposed tubular support members 14 are affixed at the front of the scaffold 10, and each member 14 has an elongated hollow sleeve 16 mounted therein. Each of the sleeves 16 has, in turn, a post 18 telescopically received therein and extending from the upper end thereof, and from the lower end of each sleeve 16 projects a rigidly secured pin 20 for mounting within the tubular support members 14. Thumb screws 22 are provided adjacent the upper ends of the sleeves 16 for fixing the posts 18 at adjusted positions therewithin.

As is best seen in FIG. 3, a cap 24 is threadably engaged upon the upper end of each of the posts 18, and a generally U-shaped bracket 26 is brazed, welded or otherwise rigidly secured upon each of the caps 24. The brackets 26 engage about the shoulders of the lower flange 28 of an elongated I-bearn member 30, and a pad 32 of felt or other protective material is provided about the upper flange 34 of the I-beam member 30 along substantially its entire length, thus providing a cushioned, planar support surface 36 thereon. Inserted within the l-beam member 30 at two locations spaced along its length are leveling devices or vials 38 and a retractable tape measure 40 is secured adjacent one end 41 thereof.

in accordance with the method of the invention, and with additional reference to FIG. of the drawings, as an initial step in the erection of a suspended ceiling, right angle flanges or wall brackets 50 are first secured to the walls (A and B being shown) about the periphery of the room at a predetermined height and at a horizontal attitude. A sufficient number of wire hangers 44 are affixed at appropriate locations to the ceiling joists 46 or to other overhead structure that may be provided. The end 47 of the I-beam 30 is then positioned beneath the lip 50 of the bracket 42 secured to wall A, and the attitude of l-beam 30 is adjusted to a horizontal position, as indicated by leveling devices 38. Since the lip 50 is usually of a relatively thin construction, its influence upon height can normally be ignored, for practical purposes. However, the end 47 of the I-beam 30 may simply be placed adjacent to the lip 50 to ensure that the planar surface 36 thereof lies in the same plane as the upper surface of the lip 50, if so desired. Upon achieving a horizontal attitude, the thumb screws 22 in the sleeves 16 are tightened against the posts 18 to fix the l-beam 30 in the desired position. The distance between the end 41 of the l-beam 30 and the floor 52 may be measured with the metal tape 40 both initially as a rough check of the proper angular position and also to ensure the accommodation of floor variations, especially over long expanses thereof.

After the l-beam 30 has been fixed in the proper position, a first main run T-bar 48 is emplaced with oneend resting upon the upper surface of the lip 50 of the bracket 42 secured to wall B, and with the opposite end thereof resting upon the support surface 36 of the I- bcam 30. Ends of the appropriate wire hangers 44 are then inserted through holes 54 provided in the T-bars, to wire the T-bars in the desired position. As will be appreciated, a series of main run T-bars 48 is installed with the T-bars 48 placed at spaced locations along the length of wall B, to the extent permitted by the length of I-beam 30. Thereafter, the scaffold may be moved as necessary to complete the installation of T- bars 48 across the room, using the leveling devices 38 and tape measure 40 to ensure that the frame grid, and consequently the suspended ceiling, are at the correct and uniform height. After installation of the main run T-bars 48, a series of cross T-bars (not illustrated) will normally be installed at spaced locations between and perpendicular to adjacent'main run T-bars 48 (or between a main run T-bar 48 and the right angle bracket 42 along the wall A) to define a suspended grid having appropriately dimensioned subdivisions for the support of acoustic tiles or other ceiling panels in a conventional manner.

Typically, the elongated support member will be on the order of about 20 30 feet in length, and most desirably it is about 24 feet long. It may conveniently be provided by an l-beam such as that shown in the drawing, which may be about three inches high, or the elongated member may simply be a length of bar stock. As regards the element supoorting the elongated support member above the scaffold, the hollow sleeves 16 referred to in the drawing may be about 4 5 feet in length and of a diameter of about 1 to 2 inches. The posts (18 in the drawing) may also be provided by tubular members and will preferably be about i k to 3 feet long. The diameter of the posts will depend to a measure upon the inside diameter of the sleeves in which they are to telescopically seat, and a l A inch pipe has been conveneinetly used for the outer sleeve with a 1 inch pipe serving as the inner post.

Although the hollow sleeve may itself be relatively permanently affixed to the scaffold, it is most desirable to utilize a sleeve which is readily disengageable from a support member on the scaffold. A particularly convenient mode of construction is illustrated and employs the same diameter pipe for the support member on the scaffold and the sleeve, with a smaller diameter stud extending from one end of either member. The stud simply seats in the open end of the corresponding member, and may be provided by a pin inserted into one end of the pipe and welded or brazed in place. Alternatively, a larger diameter support member may be employed to telescopically receive the sleeve, with a ring or collar being provided on the sleeve to function as a stop to assure positioning in the proper relationship. Although support for the elongated member at two locations is normally adequate, additional posts andsleeves may be advantageously provided, particularly in the larger assemblies.

As has previously been mentioned, use of the present method and apparatus effects a considerable increase in the efficiency and speed with which suspended ceiling installations may be made, and increases in installation rates of percent or more have been realized in practice by use of the invention. More specifically, whereas the techniques hereinbefore known normally permit the installation of about 2,500 square feet of ceiling grid per man day, the present-invention enables installation of about 5,000 square feet of grid per man day.

Accordingly, it can be seen that the present invention provides a novel method of erecting a suspended ceiling, which is relatively facile and rapid compared to conventional methods, and which results in a ceiling that is horizontal and at a uniform distance above the floor. The invention also provides a novel assembly for use in carrying out the method,-which assembly may be produced relatively simply and economically, and is facile and convenient to employ.

Having thus described the invention, we claim:

1. An assembly for use in erecting a suspended ceilmg comprising:

a. a mobile scaffold including at least four vertically extending frame members, a plurality of supporting frame members extending transversely between said four vertically extending frame members and an elevated platform supported on said plurality of supporting frame members, each of said four vertically extending frame members having one end thereof engaging a floor surface and the other end thereof positioned adjacent said elevated platform, said other end of each of said four vertically extending frame members including mounting means comprising a pin-receiving opening;

b. a pair of vertically extending sleeves having telescoping means supported for adjustment relative thereto at one end thereof and having mounting means comprising a pin secured at the other end thereof cooperable with said pin-receiving openings of said four vertically extending frame members for insertion therein for detachably mounting an elongated support member having a substantially planar upper surface and being supported on said holding means for said pair of telescoping posts whereby said elongated support member and thereby said elongated planar upper surface thereof is secured selectively in one of a multiplicity of positions above said elevated platform by adjusting said pair of telescoping posts relative to said pair of vertically extending sleeves; and

d. leveling means supported on said elongated support member to indicate the relationship of said planar upper surface to horizontal.

2. The assembly for use in erecting a suspended ceiling as set forth in claim 1 further comprising a device secured on said elongated support member for measuring the vertical distance from said elongated support member to a horizontal surface, and wherein said holding means includes a cap threadedly engaged upon the upper end of each of said telescoping posts, and a substantially U-shaped bracket secured upon each of said caps for engagement with said elongated support member. 

1. An assembly for use in erecting a suspended ceiling comprising: a. a mobile scaffold including at least four vertically extending frame members, a plurality of supporting frame members extending transversely between said four vertically extending frame members and an elevated platform supported on said plurality of supporting frame members, each of said four vertically extending frame members having one end thereof engaging a floor surface and the other end thereof positioned adjacent said elevated platform, said other end of each of said four vertically extending frame members including mounting means comprising a pin-receiving opening; b. a pair of vertically extending sleeves having telescoping means supported for adjustment relative thereto at one end thereof and having mounting means comprising a pin secured at the other end thereof cooperable with said pin-receiving openings of said four vertically extending frame members for insertion therein for detachably mounting said pair of vertically extending sleeves on two of said four vertically extending frame members, said telescoping means comprising a pair of telescoping posts having one end thereof adjustably mounted on said one end of said pair of vertically extending sleeves and having holding means provided at the other end thereof; c. an elongated support member having a substantially planar upper surface and being supported on said holding means for said pair of telescoping posts whereby said elongated support member and thereby said elongated planar upper surface thereof is secured selectively in one of a multiplicity of positions above said elevated platform by adjusting said pair of telescoping posts relative to said pair of vertically extending sleeves; and d. leveling means supported on said elongated support member to indicate the relationship of said planar upper surface to horizontal.
 2. The assembly for use in erecting a suspended ceiling as set forth in claim 1 further comprising a device secured on said elongated support member for measuring the vertical distance from said elongated support member to a horizontal surface, and wherein said holding means includes a cap threadedly engaged upon the upper end of each of said telescoping posts, and a substantially U-shaped bracket secured upon each of said caps for engagement with said elongated support member. 